Block and buidling construction using same

ABSTRACT

A building construction utilizes hollow modular masonry blocks, each provided with at least one centrally disposed full-size cavity and one half-size cavity as defined by cross webs joining a pair of parallel sidewalls. The sidewalls terminate, at least at one end, in freely projecting extensions each having a distal inturned end flange adapted to laterally abut a similar construction of an adjacent block. The shoulder as provided behind each end flange serves to position and retain full-length vertically installed reinforcing bars through unobstructed vertically aligned cavities in the successive courses of the blocks from floor to floor while recesses in the top of each web receive horizontal reinforcing elements and permit the communication of a filler of concrete both horizontally and vertically throughout the wall.

[ 511 Feb. 27, 1973 BLOCK AND BUIDLING CONSTRUCTION USING SAME [76]Inventor: Paul A. Wood, 3215 Franklin Rd.,

S.W., Roanoke, Va. 24014 22 Filed: Jan.6, 1972 21 Appl.No.: 215,766

155,454 0/1920 Great Britain ..52/284 1,005,191 12/1951 455,308 2/1950417,630 1/1947 ltaly ..52/496 Primary Examiner.lohn E. Murtagh AssistantExaminer-James L. Ridgill, Jr. Attorney-Em0ry L. Groff et al.

[57] ABSTRACT A building construction utilizes hollow modular masonryblocks, each provided with at least one centrally disposed full-sizecavity and one half-size cavity as defined by cross webs joining a pairof parallel sidewalls. The sidewalls terminate, at least at one end, infreely projecting extensions each having a distal intumed end flangeadapted to laterally abut a similar construction of an adjacent block.The shoulder as provided behind each end flange serves to position andretain full-length vertically installed reinforcing bars throughunobstructed vertically aligned cavities in the successive courses ofthe blocks from floor to floor while recesses in the top of each webreceive horizontal reinforcing elements and permit the communication ofa filler of concrete both horizontally and vertically throughout thewall.

8 Claims, 30 Drawing Figures PATENTEUFEBZTI975 3.711. 967

SHEET E OF 4 BLOCK AND BUIDLING CONSTRUCTION USING SAME This inventionrelates generally to building construction, and more particularly, to animproved modular masonry block and a unique arrangement of a pluralityof such blocks resulting in a more desirable building construction.

Hollow, modular type building blocks are generally well known wherein acementious composition such as concrete or concrete/cinder material ismolded or cast to provide a plurality of blocks having verticallyextending passageways or cavities and which are laid up in multiplecourses with the end mortar joints of successive courses disposed instaggered relationship. Likewise, it is also known in the art to fillthe cavities formed in the blocks with reinforced concrete such that amonolithic-like wall construction is produced.

By the present invention, a unique arrangement is provided wherein bothhorizontally and vertically extending steel reinforcing elements arecombined with modular blocks of improved construction and a reinforcingfiller of concrete to yield a monolithic structural installation havingvastly superior strength components in both the horizontal and verticalplanes. It is acknowledged that the inclusion of both the steel andreinforcing concrete in a modular block-type wall construction in itselfisnot unique; yet the herein proposed construction provides an improvedblock configuration readily lending itself to a rapid erection of thebuilding walls while offering positive positioning means for locatingand retaining both the horizontally and vertically extending steelreinforcing elements. The present concept will be understood to beadaptable to building blocks as utilized for constructing a straightwall section as well as for erecting the corners or intersection of twoor more walls while also setting forth a unique arrangement for tying-inintermediate load-bearing walls of the building, all of which results ina monolithic type of building construction obviating the necessity ofutilizing common structural steel components such as beams or columns,yet resulting in a structure having a most desirable load distributionfactor throughout all the various walls forming the building.

Accordingly, one of the primary objects of the present invention is toprovide an improved masonry building block offering a modularconstruction containing means for positively locating and retaining bothhorizontally and vertically extending steel reinforcing elements.

Another object of the present invention is to provide an improvedmasonrybuilding block of the modular type including at least a pair ofsidewall extensions each having an inwardly turned end flange.

Still another object of the present invention is to provide an improvedmodular building block having a pair of parallel sidewalls joined by aplurality of parallel cross webs and wherein the top and bottom surfacesof these webs are inwardly offset from the plane of the top and bottomsurfaces of the block sidewalls and further include a plurality ofhorizontally extending reinforcing rod receiving grooves.

A further object of the present invention is to provide an improvedbuilding construction including a plurality of modular masonry blocksdisposed in a plurality of vertically offset courses and providing opencavities extending freely from the top of the wall to the bottom of thewall and also communicating laterally from one side edge of the wall tothe other side edge thereof for the reception of both metal reinforcingelements as well as a filler of reinforcing concrete such that a wall isprovided having a plurality of unobstructed concealed vertical concretecolumns.

With these and other objects in view which will more readily appear asthe nature of the invention is better understood, the invention consistsin the novel construction, combination and arrangement of partshereinafter more fully described, illustrated and claimed.

A preferred and practical embodiment of the invention is shown in theaccompanying drawings, in which:

FIG. 1 is a perspective view of a standard stretcher course buildingblock according to the present invention.

FIG. 2 is an end elevation of a typical block according to the presentinvention.

FIG. 3 is a top plan view of. a segment of a typical buildingconstruction accordingto the present invention and illustrates thearrangement of an odd-num bered course of blocks. a

FIG. 4 is a perspective view of the corner block as shown in FIG. 3.

FIG. 5 is a perspective view of the T-block as used in the intersectionof walls as shown in FIG. 3.

FIG. 6 is a top plan view illustrating a typical adjacent oreven-numbered course of blocks associated with the construction shown inFIG. 3.

FIG. 7 is a perspective view of a companion corner block as used withthe even-numbered course of FIG. 6.

FIG. 8 is a perspective view of a half-size block as used with theeven-numbered course of FIG. 6 to provide a door or window jamb opening.

FIG. 9 is a perspective view of a three-quarter size stretcher companionblock as used in the course 0 FIG. 6 to tie in an interior wall with aT. 1

FIG. 10 is a perspective view of a full-size stretcher course jambblock.

FIG. 11 is a perspective view of a corner block as used in the course ofFIG. 6.

FIG. 12 is a vertical end sectional view taken through a typical blockof the present invention.

FIG. 13 is a vertical sectional view through a plurality of courses ofblocks as arranged to provide two intersecting walls and illustrates theconcealed unobstructed vertical columns formed by the tiller ofconcrete.

FIG. 14 is a fragmentary top plan view of a typical corner asconstructed withprior art-blocks.

FIG. 15 is a perspective view of the prior art blocks of FIG. 14.

FIGS. 16 through 30 are top plan views of various blocks constructedaccording to the present invention.

Similar reference characters designate correspond- .ing parts throughoutthe several figures of the drawings.

sidewalls as well as the lower horizontal surfaces 4-4 thereof will beunderstood to be coplanar with respect to one another, while asignificant feature of the present invention is the vertically displacedtop and bottom horizontal surfaces 5 of the webs 2, which surfaces willbe seen to be dropped or displaced inwardly from the plane of thesurfaces 3 and 4 of the sidewalls 1. It will be understood that theblock B as shown in this figure represents a typical constructioncarrying out the unique concept of the present invention. This specificblock is intended to serve in the construction of a wall at points'otherthan a corner thereof, adjacent a window or door jamb or intersectionwith an interior wall,

sects with a rearwardly directed or inclined wall 8 forming a shoulder,as shown most clearly in FIG. 3. The outer face 9 of each sidewall endflange 7 extends normal to the longitudinal dimension of the block for adistance approximately twice the thickness of the sidewall 1 and isprovided with a pair of vertically extending mortar-receiving grooves 10throughout its height. The provision of more than one such mortar grooveon each outer face has been found to significantly improve the lateralmortar bond between adjacent blocks with a marked increase inweatherproofin g at this normally vulnerable joint.

Associated with the aforedescribed dropped horizontal surfaces 5 on thecross webs 2, are a pair of longitudinally and horizontally extendinggrooves 11, located adjacent the two side walls 1 such that a lineextending through the grooves l l in one web 2 and the respectivegrooves 11 in another web 2 will be seen to be juxtaposed the distalportions 7 of the inturned end flanges 7, for reasons which will becomeobvious hereinafter. All forms of the block as proposed by the presentinvention are preferably symmetrical with respect to the top and bottomportions thereof. This feature is illustrated most clearly in FIG. 2,wherein it will be seen that both horizontal surfaces 5-5 of the web 2are dropped inwardly with respect to the upper and lower surfaces 3 and4 of the adjacent sidewalls such that a significant clearance or recess5 is produced adjacent both the top and bottom of each web 2. Thisarrangement serves to increase the efficiency of labor duringconstruction of a building by means of the present blocks, since itisnot necessary for the workers to turn over most forms of block whenplacing each course in position. An exception would be when using thecompanion corner block of FIG. 7. This block is still symmetrical withrespect to its upper and lower faces but includes a single sidewallsection 6 at one end and accordingly may require inversion duringcertain installation situations.

The spaced-apart webs 2-2 of any block will be seen to define a fullcavity C therebetween while the end portions of the blocks encompassedby the pairs of extended sidewall sections each substantially define ahalf cavity C. Accordingly, when any two blocks in a course are laidend-to-end with a proper mortar joint M between the juxtaposed outerfaces 9,, a full cavity is in effect produced between the opposed websof the two adjacent blocks.

A typical assembly of the blocks of this invention will be understood bya review of FIGS. 3 and 6 of the drawings. FIG. 3 may be considered torepresent a fragmentary illustration of one course of various blocksincorporating the present invention as assembled in producing the cornerof a building and which includes an interior load-bearing wall I, whileFIG. 6 will be understood to disclose the arrangement of the presentblocks as they would appear in the previous as well as the nextsucceeding course, immediately adjacent the course of FIG. 3. For easeof description, the course shown in FlG. 3 is referred to as a typicalodd-numbered course 12. In other words, this arrangement of blocks mayappear as the starter or first course as well as each alternate orodd-numbered course thereafter while the arrangement of FIG. 6 willappear alternately as the even-numbered courses 13.

The block B of FIG. 1, as described hereinbefore, is the standardstretcher course block, and it will be appreciated that any number ofthese blocks B are positioned in end-to-end relationship as required tocomplete the specified extent of either outer wall 0 from one corner tothe next corner thereof.

The present invention provides novel means for insuring the continuationof the concealed vertical concrete columns as well as the horizontal andvertical metallic reinforcing throughout the entire building wallconstruction by including a number of special blocks for use at corners,intersections with interior walls, adjacent door or window openings,etc. In the corner block B as used with the odd-numbered course 12, theconstruction will be seen to besomewhat similar to that of the block Bin that a full cavity C is bounded by two cross webs 2-2 each of whichdefine a half cavity C on the opposite side thereof. The apparentdistinction here is that the two pairs of extended sidewall sections 6and their respectivehalf cavities C' are disposed at right angles withrespect to the full cavity C.

In order to carry out the present concept in a building construction atthe point on the course 12 where an intermediate wall I is provided,an'additional type of block may be utilized, as shown in FIG. 5. In thecourse illustrated in FIG. 3, a T-block, generally designated 8, issubstituted for one of the blocks B at the point where the interior wallI is designed to join the exterior wall 0, it being understood that theoverall length of the sidewall 14 of the block I3 is identical to thatof the sidewall l of the stretcher course block B. The opposite sidewallof the block B includes a pair of extensions 15-15 which intersect atright angles to the adjacent extensions 6-6 and, like the otherextensions, provide a half-size open cavity C therebetween. In thisblock, the intermediate portion of the adjacent sidewall in effectcomprises a web 16 having the same configuration and construction as theaforedescribed webs 2.

Side-stepping the application of the horizontal metal reinforcing rodsat this point, the next succeeding course to follow course 12 willcomprise a plurality of blocks arranged to insure continuity of thedesired concealed vertical concrete columns while precluding theexistence of vertically adjacent mortar joints M. This next'course,referred to as an even-numbered course 13, may include the arrangementof FIG. 6, which will be understood to overlie the course of FIG. 3 withan appropriate horizontal mortar joint M therebetween. The standardstretcher course block B is laid upon course 12 to complete the straightrunning lengths of course 13 not involving a special feature aspreviously described. Quite obviously, each stretcher course block B islaid such that its full cavity C is centrally disposed above thevertical mortar joint M bounded by two half cavities C of the blocksbelow.

At the intersection of the two outer walls 0-0, 3 3 6 at 3 17-4 4 18--it will be obvious that the corner block B could not be used in layingthe even-numbered course 13 as this would result in vertically adjacentmortar joints M, not to mention the existence of an odd-size gap betweenthe two adjacent stretcher course blocks B. Accordingly, a specialcompanion corner block B will be readily apparent from a review of FIG.7 wherein it will be seen that this block is similar in length andoverall construction to the standard stretcher block B with theexception that the block B is minus one extended sidewall section at oneThe concept of the present invention may be carried out by utilizingjamb blocks of various lengths to define 'door or window openings. FIG.6 illustrates the use of a full-size stretcher course jamb block B inthe interior wall I. This block, which is also shown in FIGS. and I7, issimilar to the standard stretcher course block B except for one endthereof which is devoid of the pair of end flanges 7-7 and instead isprovided with a jamb face 19 enclosing one end of the block and defininga partial half-size cavity 20 between its body and the adjacent crossweb 2.

end thereof. The sidewall 1, in the area of the missing section 6, isprovided with an outside bevel corner 17 disposed at an angle of 45.With this one form of block a corner may be constructed by using twoblocks B arranged as shown in FIG. 6 with the respective bevel corners17-17 juxtaposed with an appropriate mortar joint M therebetween. Thecorner is then completed by the application of the corner block Bshownin FIGS. 6'

and 11. The block Bcomprises two sidewalls 18-18 disposed at rightangles and of equal length. The distal portion of each sidewall 18 isprovided with the same end flange 7 and attendant structure asthepreviously described blocks sothat upon installation as shown in FIG.6 a full cavity C will be formed which is in alignment with the fullcavities of the vertically adjacent courses.

In the formation of the even-numbered course of blocks in the area ofthe interior wall I, a different type of construction than that of theunderlying course 12 is also used in order to provide the desiredstructural tiein between courses-at this point, and like throughout thebuilding construction, to preclude vertically adjacent blocksjfromhaving overlying joints. At the point of intersectionbetween theinterior wall I and the outer wall 0, a pair. of the same companioncorner blocks B are utilized along the outer wall 0. Again, these blocksare laid in an opposedleft-hand/right-hand relationship; however, inthis instance, the two blocks I3 are longitudinally aligned with theirrespective free-standing end flanges 7 juxtaposed as shown in FIG. 6.

Adapted to cooperate with the two blocks B at this point is athree-quarter size stretcher companion block 8', which is somewhatsimilar to the block I3 but wherein both of the sidewall extensions 6- 6at one end of the block have been removed and the resulting corners eachprovided with similar bevels l7-17. In this manner, inasmuch as the twobeveled corners of the adand/or window jambs in the outer and interiorwalls.

If the specified location of a door or window opening dictates the useof a shorter jamb block fora particular course, then the half-size jambblock l3 shown in FIGS. 6, 8 and 10 may be employed. Additionalintermediatesized jamb blocks are also disclosed. FIG. 20 illustrates athree-quarter size jamb block B while FIG. 22 shows a one-quarter sizejamb block B".

The jamb face 19 may be combined with other forms of blocks for use whena door or window opening is located adjacent a corner or T intersection.FIG. 23 illustrates a three-quarter size companion block B while afull-size companion block B is shown in FIG.

25, each provided with a bevel corner 17 and jamb face 19.

Additional special blocks shown in the drawings include the half-sizestretcher course block B of FIG. 18 which comprises a single cross web 2from which pro ject pairs of sidewall sections 6 each provided with anend flange 7.. An intersection between four walls may be constructed byuse of the double T block B shown in FIG. 27 which will be seen tocomprise a half-cavity C provided on each of the sides of four webs 2defining a full cavity C. The remaining block shown in the drawingscomprises a filler block B (FIG. 29) which includes a single web section21 having its enlarged side portions provided with the outer faces 9similar to the other-blocks.

Turning now to the erection of a building wall ac- I cording to thepresent invention, it will be understood that as each course of blocksis laid, a horizontal metal reinforcing element 22 is positioned withinthe horizontally extending grooves 11 of the webs of all adjacent blockswith a continuous length of the reinforcing elements 22 extendingthroughout the lateral extent of the walls, as shown most particularlyin FIGS. 3 and 6 of the drawings. This installation of reinforcing rodsquite obviously takes place prior to the laying of the subsequent coursewhen it is specified that each course is to be so reinforced. When aplurality of successive courses of blocks have been thus laid to aheight substantially corresponding to one floor of the building,

then a plurality of vertically extending reinforcing elements 23 arepositioned as shown in FIGS-3 and 6. The vertical reinforcing elements23 are lowered from above into the spaces 24 and 25 formed by thepreviously deposited horizontal reinforcing elements 22 and the sidewalland extension sections, respectively. Reference to FIG. 13 will mostreadily convey the resultant construction achieved after following thepresent invention. It will be seen that anyparticular verticalreinforcing element 23 will alternately pass through a space 24 inthefull cavity of one block and the space 24 in the half cavity of thevertically adjacent blocks. In view of the positive locating andretaining feature of the end flange shoulder 8 associated with each halfcavity space 25 and the captive relationship offered by the horizontalelements juxtaposed each end flange surface 7 it will be appreciatedthat an exacting positioning of both the horizontal and verticalreinforcing elements is achieved throughout both the vertical andlateral extent of all of the walls of the building.

After the installation of the vertical reinforcing elements has beencompleted, all of the exposed cavities within the assembled blocks arefilled from the uppermost course with any suitable cementious materialsuch as concrete. This filler 26 of concrete is formulated of such aconsistency to insure that as it is being poured into the openings ofthe uppermost course of blocks, it will flow not only throughout thevertical extent of all f the vertically aligned cavities, but alsolaterally, in

the area of each horizontal mortar joint M, between each pair ofadjacent cavities so as to fill the recesses provided between each pairof vertically spaced apart webs of adjacent courses of blocks. In thismanner, not only do the reinforcing elements 22 and 23 provide bothhorizontal and vertical stability to the completed wall construction,but also, it will be appreciated that the concrete filler 24 extendsboth vertically and horizontally throughout all the wall construction toproduce a monolithic construction of maximum strength with totalcommunication between all adjacent blocks, both vertically andhorizontally by means of the reinforcing elements and concrete filler.

The arrangement shown in FIGS. 14 and is a compromise constructionwherein certain of the present blocks are disposed in a manner suggestedby the prior art. It will be seen that such an assembly fails to makeuse of the teaching herein whereby unique corner blocks are provided topreclude the formation of vertical mortar joints parallel with the faceof a wall.

I claim:

1. A building construction comprising a plurality of intersecting walls,said walls including a plurality of stacked courses of hollow blocks, aplurality of said blocks having a pair of spaced-apart sidewalls, a pairof cross webs having top and bottom surfaces joining said sidewalls anddefining a full cavity therebetween, a pair of extended sidewallsections projecting from at least one said cross web and defining a halfcavity therebetween, a pair of flanges extending inwardly from the endof said sidewall sections and provided with opposed distal surfaceportions adjacent a rearwardly facing shoulder, each said flangeincluding an outer face disposed substantially normal to the runninglength of said sidewall section and having a width substantially equalto twice the thickness of each said sidewall section, said web topsurfaces in a plane disposed substantially below that of said sidewallsto provide a recess thereabove and having transverse grooves thereinadjacent one said sidewall and extending below the plane of said web topsurfaces, said blocks of vertically adjacent courseslongitudinallystaggered with respect to each other whereby the fullcavity of one said course block is vertically adjacent upper and lowerdisposed pairs of abutting block half cavities thereby providing aplurality of adjacent vertical cavities of equivalent cross-sectionalarea throughout the vertical extent of said walls, a horizontalreinforcinghelementdisposed within said rooves in said webs Wl itsperiphery passing imme iately ad- 10 jacent said flange distal surfaceportion, a plurality of vertical reinforcing elements each extendingalternately through full and half cavities of vertically adjacent blocksof said courses of blocks, each said vertical reinforcing elementpassing through said half cavity being captivated intermediate saidflange shoulder and cross web and between said block sidewall and saidhorizontal reinforcing element thereby restricting the lateral positionof each said vertical reinforcing rod as it passes through said fullcavities of the vertically adjacent blocks, a body of poured concretefilling said vertical cavities throughout the vertical extent of saidwalls to provide a plurality of adjacent uninterrupted reinforcedconcrete columns and said poured concrete extending laterally betweenthe spaced apart vertically adjacent block cross webs to fill saidrecesses and interlock adjacent said columns.

2. A building construction according to claim 1 wherein, the distancebetween said flange distal portion and said horizontal reinforcingelement is less than the thickness of said vertical reinforcing element.

3. A building construction according to claim 1 wherein, each said outerface includes a plurality of vertical grooves.

4. A building construction according to claim 1 wherein, a plurality ofsaid blocks are provided with sidewalls intersecting one another to formcorner blocks, and said corner blocks include a pair of cross websdisposed in planes normal to each other.

5. A building construction according to claim 1 wherein, said blockincludes an end wall bridging a pair of said sidewall sections to closesaid half cavity therebetween.

6. A building construction according to claim 1 wherein, a plurality ofsaid blocks includes a single ex-

1. A building construction comprising a plurality of intersecting walls, said walls including a plurality of stacked courses of hollow blocks, a plurality of said blocks having a pair of spaced-apart sidewalls, a pair of cross webs having top and bottom surfaces joining said sidewalls and defining a full cavity therebetween, a pair of extended sidewall sections projecting from at least one said cross web and defining a half cavity therebetween, a pair of flanges extending inwardly from the end of said sidewall sections and provided with opposed distal surface portions adjacent a rearwardly facing shoulder, each said flange including an outer face disposed substantially normal to the running length of said sidewall section and having a width substantially equal to twice the thickness of each said sidewall section, said web top surfaces in a plane disposed substantially below that of said sidewalls to provide a recess thereabove and having transverse grooves therein adjacent one said sidewall and extending below the plane of said web top surfaces, said blocks of vertically adjacent courses longitudinally staggered with respect to each other whereby the full cavity of one said course block is vertically adjacent upper and lower disposed pairs of abutting block half cavities thereby providing a plurality of adjacent vertical cavities of equivalent cross-sectional area throughout the vertical extent of said walls, a horizontal reinforcing element disposed within said grooves in said webs with its periphery passing immediately adjacent said flange distal surface portion, a plurality of vertical reinforcing elements each extending alternately through full and half cavities of vertically adjacent blocks of said courses of blocks, each said vertical reinforcing element passing through said half cavity being captivated intermediate said flange shoulder and cross web and between said block sidewall and said horizontal reinforcing element thereby restricting the lateral position of each said vertical reinforcing rod as it passes through said full cavities of the vertically adjacent blocks, a body of poured concrete filling said vertical cavities throughout the vertical extent of said walls to provide a plurality of adjacent uninterrupted reinforced concrete columns and said poured concrete extending laterally between the spaced apart vertically adjacent block cross webs to fill said recesses and interlock adjacent said columns.
 2. A building construction according to claim 1 wherein, the distance between said flange distal portion and said horizontal reinforcing element is less than the thickness of said vertical reinforcing element.
 3. A building construction according to claim 1 wherein, each said outer face includes a plurality of vertical grooves.
 4. A building construction according to claim 1 wherein, a plurality of said blocks are provided with sidewalls intersecting one another to form corner blocks, and said corner blocks include a pair of cross webs disposed in planes normal to each other.
 5. A building construction according to claim 1 wherein, said block includes an end wall bridging a pair of said sidewall sections to close said half cavity therebetween.
 6. A building construction according to claim 1 wherein, a plurality of said blocks includes a single extended sidewall section projecting from one cross web and a bevel corner is provided at the point where this latter mentioned cross web intersects the opposed sidewall.
 7. A building construction according to claim 1 wherein, a plurality of said blocks include said sidewalls terminating at one said cross web to form bevel corners at the intersection of this latter mentioned cross web and the adjacent sidewalls.
 8. A building constRuction according to claim 1 wherein, said blocks are symmetrical about both horizontal and vertical bisecting planes. 